All machines from the category Gear shaping machine

How a gear shaping machine works

A gear shaping machine is a machine tool for the manufacturer of internal and external gears using the gear shaping process. This production method is particularly suitable for internal gears that are difficult to access and for workpieces with large diameters or complex geometries. In contrast to gear hobbing, gear shaping does not rotate, but works with a linear shaping motion, which makes it ideal for internal gears.

A cutting shaping head - usually in the form of a gear shaping gouge - is used during the machining process. This has the negative profile of the gear to be produced and moves up and down axially. During this shaping movement, the workpiece rotates in synchronisation with the movement of the tool. The tool and the workpiece are coupled in such a way that their relative movement corresponds to the rolling movement of two gears - hence the name gear shaping.

The machining process takes place in several steps: First, the workpiece and tool are set up in the machine. Then the actual shaping process begins, in which the tool gradually removes the material and creates the desired tooth shape. The combination of the shaping movement and rotation produces precise gear manufacturing with a high surface quality. The feed movement is axial, allowing the tool to gradually penetrate deeper into the workpiece.

Modern CNC gear shaping machines enable automated, high-precision production and are capable of efficiently producing complex profile shapes and special gears. Thanks to its flexibility and precision, gear shaping is an indispensable process in gearing technology.

Other terms for this process are gear shaping as a manufacturing process, internal gear shaping or gear shaping. Gear shaping is also known as gear shaping.

Advantages of gear shaping

• Ideal for internal gears: especially in small or difficult to access workpieces
• Also possible for external gears if the workpiece is rotationally symmetrical and easy to clamp
• Very high accuracy and repeatability
• Low tool wear compared to broaching processes
• Workpiece and tool are synchronised to produce the correct tooth shape

(Gear) shaping vs broaching

Internal gears and external gears can also be produced using broaching as a manufacturing process. Frequently searched keywords for this are broaching metal and broaching mechanical engineering. Below you will find a comparison of the two manufacturing methods.

Movement principle and tool guidance

• Shaping: The tool (e.g. shaping head or gear shaping plane) performs a linear stroke movement in which it removes the workpiece. In the case of gear shaping, there is also a coordinated rotation of the workpiece, resulting in a rolling engagement.
• Broaching: The broaching tool is pulled or pushed through the workpiece in a single pass. The cutting edges of the tool are arranged in steps so that each cutting edge removes part of the material.

Areas of application

• Shaping: Very flexible in use, particularly suitable for internal gearing, small to medium quantities and complex geometries.
• Broaching: Ideal for high quantities, as the process is very fast and efficient - but usually tailored to specific component geometries and a specific tooth profile.

Tool costs and set-up times

• Shaping: Lower tool costs, higher set-up times with manual operation, but flexible with different gear manufacturing.
• Broaching: High tool costs as the broaching tool is customised, but short set-up and machining times.

Both processes deliver very precise results. However, broaching often achieves even higher repeat accuracy for large series.

Other types of gear cutting machines

Depending on the manufacturing technology used for the production of gears, we differentiate between the following gear cutting machines:

• Gear hobbing machine
• Gear skiving machine
• Gear grinding machine
• Gear shaping machine

Applications for gear shaping machines in industrial production

Gear shaping machines are used in industries where precise internal and external gears are required. Typical areas of application include the automotive industry, mechanical engineering, aerospace technology, energy technology, toolmaking, agricultural engineering and gear manufacturing.

The following workpieces, among others, can be produced with a gear shaping machine:

• Internal gears
• Clutch hubs
• Hollow shafts with internal gearing
• Synchroniser rings
• Sprockets
• Rotors for electric motors
• Planetary gear carriers
• Toothed sleeves
• Splined profiles
• Clutch rings

These workpieces are often rotationally symmetrical and require a high degree of dimensional and shape accuracy. Gear shaping is particularly suitable for medium quantities, complex profile geometries and internal gears that are difficult to access - especially where other processes such as milling or broaching reach their limits.

Gear shaping machine tools

Specially adapted tools are used in gear shaping machines to manufacture complex gear manufacturing efficiently and precisely. Typical tools are

• Gear shaping planes
• Straight-toothed shaping cutters
• Helical shaping knives
• Involute shaping tools
• Multi-wedge shaping tools
• Spline tools
• Special profile tools
• Shaping tools with interchangeable inserts
• Modular tools
• Tools with internal cooling

These tools are usually made of high-performance steel or carbide and are often coated (e.g. TiN or TiAlN) to increase tool life. Their selection depends on the workpiece geometry, tooth profile, module and material.

Accessories and operating materials for a gear shaping machine

Suitable accessories and equipment are essential for reliable operation. These include

• Workpiece clamping devices
• Tool interfaces
• Zero-point clamping systems
• Coolants and lubricants
• Chip conveyors
• Extraction systems
• Tool presetters
• Measuring and testing equipment
• CNC control software
• Cleaning and care products

These components support precision, extend the service life of the tools and ensure consistent quality in the machining process.

Leading manufacturers of gear shaping machines

In our manufacturers directory you will find companies that produce gear shaping machines for metalworking.

The following terms are frequently searched for: EMAG gear shaping machine, Gleason gear shaping machine, Höfler gear shaping machine, gear shaping Liebherr, Wägear shaping machine Liebherr, Kapp gear shaping machine, KOEPFER gear shaping machine, Monnier + Zahner gear shaping machine

Selecting the right gear shaping machine

If you want to buy a gear shaping machine, precisely harmonised specifications are crucial for the quality and efficiency of production.

• Key features include the maximum shaping height, the traverse X-axis, Y-axis and Z-axis, as well as the workpiece diameter and the clamping length.
• The number of axes is just as important. Modern CNC gear shaping machines have up to six axes for complex machining processes.
• Other criteria include the tool interface, the type of control (e.g. Siemens or Fanuc), automation capability (e.g. pallet changer, robot integration) as well as machine rigidity and vibration damping.
• Machining speed, the modular range of gear manufacturing and compatibility with standard tools also play an important role.
• The manufacturer's energy efficiency, ease of maintenance and service availability should also be taken into account.

Find the gear shaping machine that suits your production requirements now at maschinenauswahl.de.

Background: Types of gearing

There are many different types of gear manufacturing, including spur gears, helical gears, bevel gears, internal gears, external gears, spur gears, cycloidal gears, splines, spline profiles and end splines. Each type of gearing fulfils specific requirements in drive technology and power transmission.

Background: Spur gears

A spur gear is a form of gear transmission in which the gears are arranged with straight or helical teeth on cylindrical gear bodies. Power is transmitted parallel to the axis, which makes the gearbox particularly efficient and compact - practical for space-saving drive solutions. Helical gearboxes are frequently used in mechanical engineering, automation technology, conveyor systems, packaging machines, robotics and drive systems. They are characterised by high torque transmission, simple design and low maintenance costs. Variants with several transmission ratios allow flexible adjustments to Speed and force. The most important types of spur gears include spur gears, helical gears, double helical gears (end gears), internal gears and special profile spur gears for special applications.